Genset Control System Managing Power Output via Operating Modes

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing control systems for multiple generator sets struggle to efficiently manage power output to loads with fluctuating demands, leading to inefficiencies and potential equipment damage due to inadequate or excessive power supply.

Innovation Solution

A control system comprising multiple controllers and a data link that selects and implements operating modes tailored to specific power consumption scenarios, optimizing genset operations to match load requirements and ensuring efficient power distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple gensets are continuously operational to meet peak power demands, then power availability to the load is improved, but energy efficiency deteriorates due to unnecessary operation of gensets during low-demand periods

Engineering Contradiction:

Improvepower availabilityVSAvoidenergy efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The control system dynamically adjusts the operational status of gensets based on real-time load conditions. Controllers continuously monitor power demands and automatically transition gensets between operational and standby states, optimizing the balance between power availability and energy efficiency. This dynamic control eliminates the need for fixed continuous operation while ensuring adequate power supply during peak demands.

Inventive Principle:

Principle #15Dynamics

2Loss of energy

If the number of operational gensets is reduced to improve energy efficiency, then energy loss is reduced, but power availability deteriorates when sudden power demands occur

Engineering Contradiction:

Improveenergy efficiencyVSAvoidpower availability

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The control system performs preliminary actions by pre-positioning gensets in standby mode based on predicted or potential power demands. When load conditions indicate possible future demand increases, the system proactively prepares additional gensets to be quickly activated, ensuring rapid response capability while maintaining energy efficiency during current low-demand periods.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements continuous feedback monitoring of load conditions, power demands, and genset operational status. Controllers receive real-time data from the load and adjust genset operations accordingly, creating a closed-loop control system that automatically responds to changing conditions and maintains optimal balance between efficiency and reliability.

Inventive Principle:

Principle #23Feedback

3Loss of energy

If gensets are frequently switched on and off to match fluctuating power demands, then energy efficiency is improved, but system reliability deteriorates due to increased wear and potential failure

Engineering Contradiction:

Improveenergy efficiencyVSAvoidsystem stability

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The control system implements beforehand cushioning by maintaining gensets in a warm standby state rather than completely shutting them down. This intermediate state preserves essential system integrity and reduces thermal shock when gensets need to be activated, thereby minimizing wear and extending component life while still achieving energy efficiency during low-demand periods.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Device complexity

If insufficient power is provided to the load during high-demand periods, then genset operational complexity is reduced, but harmful effects increase due to potential equipment damage and operational disruptions

Engineering Contradiction:

Improvecontrol complexityVSAvoidequipment damage risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The control system acts as an intermediary between the gensets and the load, intelligently managing power distribution and genset activation sequences. This intermediary control layer coordinates multiple gensets to work together, ensuring adequate power supply during high-demand periods while simplifying individual genset operations and preventing harmful effects through balanced load management.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10491004B2Systems and methods for controlling power output to a load by multiple gensets based on load operation modes

Publication Date: 2019.11.26 CATERPILLAR INC

AI summary

A control system for a plurality of generator sets (gensets) includes a plurality of controllers and a data link. Each of the plurality of controllers is operatively associated with at least one of the plurality of gensets. The plurality of controllers is configured to control power output of each of the plurality of gensets, based on a plurality of operating modes. Each of the plurality of operating modes is configured for a power consumption scenario associated with the load. The datalink connects each of the plurality of controllers to at least one other controller of the plurality of controllers. The plurality of controllers is further configured to select a current operating mode, from the plurality of operating modes, for the plurality of gensets and control power output of at least one of the plurality of gensets based on the current operating mode.